MICROCHIP dsPIC33EP32MC204 User guide

dsPIC33EP32MC204 - Drone Propeller Reference Design User's Guide

2023 Microchip Technology Inc Page 0

dsPIC33EP32MC204 - Drone

Propeller Reference Design

User’s Guide

dsPIC33EP32MC204 - Drone Propeller Reference Design User's Guide 
 
 
Table of Contents 
Chapter 1 Introduction ............................................................................................. 0 
1.1 OVERVIEW ..................................................................................................................................... 0 
1.2 FEATURES ...................................................................................................................................... 1 
1.3 BLOCK DIAGRAM ........................................................................................................................... 2 
Chapter 2 Board Interface Description ................................................................... 4 
2.1 INTRODUCTION ............................................................................................................................. 4 
2.2 BOARD CONNECTORS ................................................................................................................... 4 
2.3 USER INTERFACE ........................................................................................................................... 7 
Chapter 3 Hardware Description ........................................................................... 11 
3.1 INTRODUCTION ........................................................................................................................... 11 
3.2 Hardware sections ...................................................................................................................... 11 
3.3 Hardware connections ................................................................................................................ 12 
Appendix A   Schematics  ..................................................................................... 17 
A.1 BOARD SCHEMATICS  .................................................................................................................. 17 
Appendix B Electrical Specifications ................................................................... 20 
B.1 INTRODUCTION ........................................................................................................................... 20 
Appendix C   Bill of Materials (BOM) .................................................................... 21 
C.1 BILL OF MATERIALS: .................................................................................................................... 21 
Appendix D Test Results ....................................................................................... 23 
 
  

dsPIC33EP32MC204 - Drone Propeller Reference Design User's Guide

2023 Microchip Technology Inc Page 0

Chapter 1 Introduction

1.1 OVERVIEW

The reference design is a low-cost evaluation platform targeted for quad copter/drone applications

with propellers driven by three-phase Permanent Magnet Synchronous or Brushless motors. This

design is based on a Microchip dsPIC33EP32MC204 DSC, a motor control device.

dsPIC33EP32MC204 - Drone Propeller Reference Design User's Guide

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FIGURE 1-1: dsPIC33EP32MC204 Drone motor controller reference design

1.2 FEATURES

Key features of the Reference Design are as follows:

• Three-Phase Motor Control Power Stage

• Phase current feedback via two shunt method for higher performance

• Phase voltage feedback to implement sensor-less trapezoidal control or flying start

• DC Bus voltage feedback for over-voltage protection

• ICSP header for In-Circuit Serial Programming using Microchip Programmer/Debugger

• CAN Communication Header

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1.3 BLOCK DIAGRAM

FIGURE 1-2: Block Diagram – Reference Design

Three Phase Inverter

Program/

Debug

Interface

User

Interface

CAN

Communication

Interface

Header P5

Gate Driver

MCP8026

+3.3V

+12V

Motor

Terminals

U,V,W

10-16 VDC

MCU Reset

ICSP

Header ISP1

Three Phase

Inverter Bridge

Shunt

Bus Current

Sensing

To

Motor

Reset

Control

IO Control – Analog, Digital, Pull-Up, Pull-Down, Remappable, Change Notification

ICSP

Program

/Debug

PWM

UART

CTMU

ADC –

Shared

Core

QEI

Timer 1

CPU

Input

Capture and

Output

Compare

Clock

SPI

I2C

ECAN1

DMT

CLC

CRC

Op Amps &

Comparators

WDT

PTG

Interrupt

Control

DMA

PWMxH/ PWMxL

Signals

Current Shunt

Feedback

Phase

Voltages

Scaling

Circuit

Phase

Voltages

PHA,

PHB

PHC

DC

Voltage

Scaling

Circuit

Input Filter

Input

Terminals

VDC and

GND

dsPIC DSC – dsPIC33EP32MC204

Speed

reference

PWM and

analog input

Header P2

Serial UART

Interface

Header P3

3.3V filter

and

feedback

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The various hardware sections of the Reference Design are shown in Figure 1-3 and summarized in

Table 1-1.

FIGURE 1-3: HARDWARE SECTIONS

Table 1-1 Hardware Sections

Section

Hardware Section

1

Three-phase motor control inverter

2

dsPIC33EP32MC204 and associated circuit

3

MCP8026 MOSFET Driver

4

CAN Interface

5

Current Sensing Resistors

6

Serial Communication Interface Header

7

ICSP™ Header

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Chapter 2 Board Interface Description

2.1 INTRODUCTION

This chapter provides a more detailed description of the input and output interfaces of the Drone motor

controller Reference Design. The following topics are covered:

• Board Connectors

• Pin functions of the dsPIC DSC

• Pin functions of the MOSFET Driver

2.2 BOARD CONNECTORS

This section summarizes the connectors in the Smart Drone Controller Board. They are shown in

Figure 2-1 and summarized in Table 2-1.

• Supplying input power to the Smart Drone Controller Board.

• Delivering inverter outputs to the motor.

• Enabling the user to program/debug the dsPIC33EP32MC204 device.

• Interfacing to CAN network.

• Establishing serial communication with the host PC.

• Supplying the speed reference signal.

FIGURE 2-1: CONNECTORS – Drone Motor Controller Reference Design

8

User Interface Header

9

DE2 MOSFET Driver Serial Interface Header

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2.2.1 ICSP™ Header for Programmer/Debugger Interface (ISP1)

The 6-pin header ISP1 can connect with the programmer, for example, PICkit 4, for programming and

debugging purposes. This is not come populated. Populate when needed with Part Number 68016-

106HLF or similar. The pin details are provided in Table 2-2.

TABLE 2-2: PIN DESCRIPTION – HEADER ISP1

Pin #

Signal Name

Pin Description

1

MCLR

Device Master Clear (MCLR)

2

+3.3V

Supply voltage

3

GND

Ground

4

PGD

Device Programming Data Line (PGD)

5

PGC

Device Programming Clock Line (PGC)

2.2.2 CAN Communication Interface Header(P5)

This 6-pin header can be used for interfacing to CAN network. The pin details are provided in Table 2-

3.

TABLE 2-3: PIN DESCRIPTION - HEADER P5

Pin #

Signal Name

Pin Description

1

3.3 V

Supplies 3.3 volts to an external module (10 ma. Max)

2

STANDBY

Input Signal to place smart controller in standby

3

GND

Ground

4

CANTX

CAN transmitter (3.3 V)

5

CANRX

CAN receiver (3.3 V)

6

DGND

Connected to the digital ground on the board

TABLE 2-1 CONNECTORS

Connector

Designator

No of

Pins

Status

Description

ISP1

5

Populated

ICSP™ Header – Interfacing Programmer/Debugger to the

dsPIC® DSC

P5

6

Populated

CAN Communication Interface Header

P3

2

Populated

Serial Communication Interface Header

P2

2

Populated

Reference Speed PWM/Analog Interface Header

PHASE A,

PHASE B,

PHASE C

3

Not

Populated

Three-Phase inverter outputs

VDC, GND

2

Not

Populated

Input DC supply tab connector

(VDC: Positive terminal, GND: Negative terminal)

P1

2

Populated

DE2 MOSFET Driver Serial Interface Header. Please refer to

MCP8025A/6 data sheet for hardware and communication

protocol specifications

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2.2.3 Speed Reference UI Header (P2)

The 2-pin Header P2 is used for providing a Speed reference to the firmware via 2 methods. The pins

are short circuit protected. Details of the header P2 are given in Table 2-4.

TABLE 2-4: PIN DESCRIPTION - HEADER P2

Pin #

Signal Name

Pin Description

1

INPUT_FMU_PWM

Digital signal – PWM 50Hz, 3-5Volts, 4-85%

2

AD SPEED

Analog signal – 0 to 3.3 V

2.2.4 Serial Communications Header (P3)

The 2-pin Header P3 can be used for accessing unused pins of the microcontroller for function

expansion or debugging, and the pin details of the header J3 are given in Table 2-4.

TABLE 2-4: PIN DESCRIPTION - HEADER P3

Pin #

Signal Name

Pin Description

1

RXL

UART - Receiver

2

TXL

UART - Transmitter

2.2.5 DE2 MOSFET Driver Serial Interface Header (P1)

The 2-pin Header P1 can be used for accessing unused pins of the microcontroller for function

expansion or debugging, and the pin details of the header J3 are given in Table 2-4.

TABLE 2-4: PIN DESCRIPTION - HEADER P1

Pin #

Signal Name

Pin Description

1

DE2

UART – DE2 Signal

2

GND

Board Ground used for external connection

2.2.6 Inverter Output Connector

The reference design can drive a three-phase PMSM/BLDC motor. Pin assignments of the connector

are shown in Table 2-6. The correct phase sequence of the motor must be connected to prevent

reverse rotation.

TABLE 2-6: PIN DESCRIPTION

Pin #

Pin Description

PHASE A

Phase 1 output of inverter

PHASE B

Phase 2 output of inverter

PHASE C

Phase 3 output of inverter

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2.2.7 Input DC Connector (VDC and GND)

The board is designed to operate in the DC voltage range of 11V to 14V, which can be powered through

connectors VDC and GND. The connector details are given in Table 2-7.

TABLE 2-7: PIN DESCRIPTION

Pin #

Pin Description

VDC

DC Input supply positive

GND

DC Input supply negative

2.3 USER INTERFACE

There are two ways to interface to the Smart Drone Controller firmware to provide a speed reference input.

• PWM input (Digital signal - PWM 50Hz, 3-5Volts, 4-55% Duty cycle)

• Analog voltage (0 – 3.3 Volts)

The interface is done via connections to the P2 connector. See Table 2-4 for details.

This reference design has an external accessory PWM controller module that provides the speed

reference. The external controller has its own potentiometer and 7 segment LED display. The

potentiometer can be used to adjust the desired speed by changing the PWM duty cycle that can be

varied from 4% to 55%. (50Hz 4-6Volts) in 3 ranges.

See Section 3.3 for more information.

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2.4 PIN FUNCTIONS OF THE dsPIC DSC

The onboard dsPIC33EP32MC204 device controls the reference design's various features through its

peripherals and CPU capability. Pin functions of the dsPIC DSC are grouped according to their

functionality and presented in Table 2-9.

TABLE 2-9: dsPIC33EP32MC204 PIN FUNCTIONS

Signal

dsPIC DSC

Number

dsPIC DSC

Pin Function

dsPIC DSC Peripheral

Remarks

dsPIC DSC Configuration – Supply, Reset, Clock, and Programming

V33

28,40

VDD

Supply

+3.3V Digital supply to dsPIC DSC

DGND

6,29,39

VSS

Digital Ground

AV33

17

AVDD

+3.3V Analog supply to dsPIC DSC

AGND

16

AVSS

Analog Ground

OSCI

30

OSCI/CLKI/RA2

External oscillator

No external connection.

RST

18

MCLR

Reset

Connects to ICSP Header (ISP1)

ISPDATA

41

PGED2/ASDA2/RP37/RB5

In-Circuit Serial

Programming

(ICSP™) or

In-circuit debugger

Connects to ICSP Header (ISP1)

ISPCLK

42

PGEC2/ASCL2/RP38/RB6

IBUS

18

DACOUT/AN3/CMP1C/RA3

High Speed Analog

Comparator 1(CMP1) and

DAC1

Amplified Bus current is further filtered

before connecting to the positive input

of CMP1 for over-current detection. The

over-current threshold is set through

DAC1. The comparator output is

internally available as fault input of the

PWM generators to shut down PWMs

without CPU intervention.

Voltage Feedback

ADBUS

23

PGEC1/AN4/C1IN1+/RPI34/R

B2

Shared ADC Core

DC Bus voltage feedback.

Debug Interface (P3)

RXL

2

RP54/RC6

Remappable Function of

I/O and UART

These signals are connected to Header

P3 to interface UART serial

communication.

TXL

1

TMS/ASDA1/RP41/RB9

CAN Interface (P5)

CANTX

3

RP55/RC7

CAN receiver, transmitter

and standby

These signals are connected to Header

P5

CANRX

4

RP56/RC8

STANDBY

5

RP57/RC9

PWM Outputs

PWM3H

8

RP42/PWM3H/RB10

PWM Module output.

Refer to the datasheet for more details.

PWM3L

9

RP43/PWM3L/RB11

PWM2H

10

RPI144/PWM2H/RB12

PWM2L

11

RPI45/PWM2L/CTPLS/RB13

PWM1H

14

RPI46/PWM1H/T3CK/RB14

PWM1L

15

RPI47/PWM1L/T5CK/RB15

General purpose I/O

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I_OUT2

22

PGEC3/VREF+/AN3/RPI33/CT

ED1/RB1

Shared ADC Core

MotorGateDr_

CE

31

OSC2/CLKO/RA3

I/O Port

Enables or disables the MOSFET

driver.

MotorGateDrv

_ILIMIT_OUT

36

SCK1/RP151/RC3

I/O Port

Overcurrent protection.

DE2

33

FLT32/SCL2/RP36/RB4

UART1

Reprogrammable port configured to

UART1 TX

DE2 RX1

32

SDA2/RPI24/RA8

UART1

Reprogrammable port configured to

UART1 RX

Scaled Phase voltage measurement

PHC

21

PGED3/VREF-/

AN2/RPI132/CTED2/RB0

Shared ADC Core

Back emf zero cross sensing PHASE C

PHB

20

AN1/C1IN1+/RA1

Shared ADC Core

Back emf zero cross sensing PHASE B

PHA,

Feedback

19

AN0/OA2OUT/RA0

Shared ADC Core

Back emf zero cross sensing PHASE A

No connections

-

35,12,37,38

-

43,44,24

-

30,13,27

2.5 PIN FUNCTIONS OF THE MOSFET DRIVER

Signal

MCP8026

Number

MCP8026

Pin Function

MCP8026 Function

block

Remarks

Power and Ground connections

VCC_LI_PO

WER

38,39

VDD

Bias generator

11-14 Volts

PGND

36,35,24,20

,19,7

PGND

Power ground

V12

34

+12V

12 Volt output

V5

41

+5V

5 Volt output

LX

37

LX

Buck regulator switch node for 3.3V out

FB

40

FB

Buck regulator feedback node for 3.3V

out

PWM output

PWM3H

46

PWM3H

Gate control logic

Refer to device datasheet for more

details

PWM3L

45

PWM3L

PWM2H

48

PWM2H

PWM2L

47

PWM2L

PWM1H

2

PWM1H

PWM1L

1

PWM1L

Current sensing pins

I_SENSE2-

13

I_SENSE2-

Motor Control Unit

Phase A shunt -ve

I_SENSE2+

14

I_SENSE2+

Phase A shunt +ve

I_SENSE3-

10

I_SENSE3-

Phase B shunt -ve. Note this shunt is

on W half bridge of the inverter.

I_SENSE3+

11

I_SENSE3+

Phase B shunt +ve. Note this shunt is

on W half bridge of the inverter.

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I_SENSE1-

17

I_SENSE1-

Motor Control Unit

Reference voltage -ve

I_SENSE1+

18

I_SENSE1+

3.3V/2 reference voltage +ve

I_OUT1

16

I_OUT1

Buffered output 3.3V/2 Volts

I_OUT2

12

I_OUT2

Amplified output Phase A current

I_OUT3

9

I_OUT3

Amplified output Phase B current

Serial DE2 Interface

DE2

44

DE2

Bias generator

Serial interface for driver configuration

MOSFET gate inputs

U_Motor

30

PHA

Gate control logic

Connects to the Motor phases.

V_Motor

29

PHB

W_Motor

28

PHC

High Side MOSFET gate drive

HS0

27

HSA

Gate control logic

High side MOSFET Phase A

HS1

26

HSB

High side MOSFET Phase B

HS2

25

HSC

High side MOSFET Phase C

Bootstrap

VBA

33

VBA

Gate control logic

Boot Strap capacitor output Phase A

VBB

32

VBB

Boot Strap capacitor output Phase B

VBC

31

VBC

Boot Strap capacitor output Phase C

Low Side MOSFET gate drive

LS0

21

LSA

Gate control logic

Low side MOSFET Phase A

LS1

22

LSB

Low side MOSFET Phase B

LS2

23

LSC

Low side MOSFET Phase C

Digital I/O

MotorGateDrv

_CE

3

CE

Communication port

Enables the MC8026 MOSFET driver.

MotorGateDrv

_ILIMIT_OUT

15

ILIMIT_OUT ( Active low)

Motor Control Unit

No connects

-

8

LV_OUT1

-

4

LV_OUT2

-

6

HV_IN1

-

5

HV_IN2

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Chapter 3 Hardware Description

3.1 INTRODUCTION

The Drone Propeller Reference Design Board is intended to demonstrate the capability of the small pin

count motor control devices in the dsPIC33EP family of single core Digital Signal Controllers (DSCs).

The control board incorporates bare minimal componentry to reduce weight. The PCB area could be

further shrunk in size for the production intent version. The board can be programmed via the In System

Serial Programming connector and incorporates two current sense resistors and a MOSFET driver. A

CAN interface connector is provided for communication with other controllers and to provide reference

speed information if needed.

The controller’s inverter takes an input voltage in the range of 10V to 14V and can deliver a continuous

output phase current of 8A (RMS) in the specified operating voltage range. For more information on

electrical specifications, see Appendix B. “Electrical Specifications”.

3.2 HARDWARE SECTIONS

This chapter covers the following hardware sections of the Drone Propeller Reference Design Board:

• dsPIC33EP32MC204 and associated circuitry

• Power Supply

• Current Sense Circuitry

• MOSFET gate driver circuitry

• Three-Phase Inverter Bridge

• ICSP Header/Debugger Interface

3.2.1 dsPIC33EP32MC204 and associated circuitry

3.2.2 Power Supply

The controller board has three regulated voltage outputs 12V, 5V and a 3.3V generated by the

MCP8026 MOSFET driver.

The 3.3 volts is generated using the MCP8026 onboard buck regulator and a feedback

arrangement. See red box in FIGURE A-1 in the schematics section.

The external power supply from the battery is directly applied to the inverter via the power

connectors. A 15uF capacitor provides the DC filtering for stable operation during rapid load changes.

Please see device (MCP8026) data sheet for output current capability of each voltage output.

3.2.3 Current Sense Circuitry

Current is sensed using the popular “two shunt” approach. Two 10 milliohm shunts provide the

current input to the inputs of the on-chip Op-Amps. The Op-Amps are in differential gain mode with a

gain of 7.5 providing a 22Amp peak phase current measurement capability. The amplified current signal

from phase A (U half-bridge) and Phase B (W half-bridge) is converted by the dsPIC controller firmware.

A voltage reference with a buffered output for 3.3V / 2 provides for noise free zero reference for

the current sense circuits.

See Schematics section FIGURE A-4 for details.

3.2.4 MOSFET gate driver circuitry

The gate drive is handled internally except for the bootstrap capacitors and diodes which are

located on the board and designed keeping in mind to adequately turn ON the MOSFETs at the lowest

operating voltage. See specifications for MCP8026 operating voltage range in the data sheet.

See Schematics section FIGURE A-1 for interconnect details.

3.2.5 Three- Phase Inverter Bridge

The inverter is the standard 3 Half bridges with 6 N Channel MOSFET devices capable of

operation in all the 4 quadrants. The MOSFET driver directly interfaces through the slew rate limiting

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series resistors to the Gates of the MOSFETs. A standard boot strap circuit comprising of a network of

capacitors and diodes is provided for each of the high side MOSFETs for adequate turn ON gate voltage.

The bootstrap capacitors and diodes are rated for full operating voltage range and current.

The output of the three-phase inverter bridge is available on U, V and W for the three phases of

the motor.

See Schematics section FIGURE A-4 for connectivity and other details.

3.2.6 ICSP Header/Debugger Interface

Programming the Smart Drone Controller board:

Programming and debugging are via the same ICSP connector ISP1. Use the PICKIT 4 to

program with the PKOB connector, connected 1 to 1 as given in table 2-2. You can program either with

the MPLAB-X IDE or MPLAB-X IPE. Power up the board with 11-14 Volts. Select the appropriate hex

file and follow instructions on the IDE/IPE. Programming is complete when a “Programming/Verifying

complete” message is displayed in the output window.

Refer to MPLAB PICKIT 4 data sheets for debugging instructions.

3.3 HARDWARE CONNECTIONS

This section describes a method to demonstrate the operation of the Drone controller. The reference

design requires a few extra off-board accessory modules and a motor.

• A 5V power supply to the PWM controller

• PWM controller used to supply a speed reference or a potentiometer to supply a varying voltage

speed reference

• A BLDC motor with parameters as described in Appendix B

• A battery power source of 11-14V and 1500mAH capacity

Any compatible make or model can be used to replace the ones shown here for successful operation.

Shown below are examples of the above accessories and motor used for this demonstration.

5V switching regulator:

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PWM Controller:

BLDC motor: DJI 2312

Battery:

Operating instructions:

Follow the steps as below:

Note: DO NOT ATTACH THE PROPELLER AT THIS TIME

Step 1: Main power source connection

Connect the battery ‘+’ and ‘-‘ to the VDC and GND terminals to power the smart controller.

A DC power supply can also be used.

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Step 2: Speed reference signal to the smart Drone controller.

The controller takes speed input reference from the PWM controller at 5V max peak. The output

of the PWM controller provides a ground referenced 5V signal output that connects to a 5V tolerant input

pin as shown in the picture. Also shown is the location for the ground connection.

Step 3: Power supply to the PWM controller.

Connect the Switching regular input to the battery terminals and the output (5V) to the PWM

controller supply.

Step 4: PWM controller configuration:

The signal pulse width is from the PWM controller is validated for a valid signal in firmware to

prevent spurious turn ON and over speeding.

The controller has two push button switches. Select the manual mode of operation using the

“Select” switch.

Use the “Pulse Width” button to select between 3 levels of speed control. The switch cycles

through 3 ranges for PWM duty cycle output with each press.

Range 1: 4-11%

Range 2: 10-27.5%

Range 3: 20-55%

The display indication varies from 800 to 2200 for a linear change in duty cycle within the range.

Turning the potentiometer on the PWM controller will increase or decrease the PWM output.

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Step 5: Motor terminal connection:

Connect the motor terminals to PHASE A,B and C. The sequence decides the direction of

rotation of the motor. The desired rotation of the Drone is clockwise looking into the motor to prevent the

propellar from loosening. It is therefore important to confirm the rotation direction before mounting the

blades.

Supply a PWM reference signal by tweaking the potentiometer on the PWM controller starting

with the least pulse width position (800). The motor will start spinning at 7.87% duty cycle (50Hz) and

above. The 7-Segment display shows 1573 (7.87% duty cycle) to 1931 (10.8% duty cycle) when the

motor spins. Confirm the direction of rotation is counterclockwise. If not swap any two connections to the

motor terminals.

Return the potentiometer to the lowest speed setting.

Step 6: Mounting the Propeller:

Disconnect battery power. Mount the propeller blade by screwing it into the motor shaft in the

clockwise direction. Hold the stick/motor firmly with arm stretched out and at a safe distance from all

obstacles and people while in operation. Connect the power supply. The propeller action will exert force

against the hand when spinning, so a firm grip is essential to prevent bodily injury. Tweak the

potentiometer to change the speed (display indicates between 1573 and 1931)

This completes the demonstration.

dsPIC33EP32MC204 - Drone Propeller Reference Design User's Guide

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The below picture shows the overall wiring setup for the demonstration.

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Appendix A Schematics

A.1 BOARD SCHEMATICS

This section provides schematics diagrams of the dsPIC33EP32MC204 Drone Propeller Reference

Design. The reference design uses a four-layer FR4, 1.6 mm, Plated-Through-Hole (PTH) construction.

Table A-1 summarizes the schematics of the Reference Design:

TABLE A-1: SCHEMATICS

Figure

Index

Schematics

Sheet No.

Hardware Sections

Figure A-1

1 of 4

dsPIC33EP32MC204-dsPIC DSC(U1) Interconnections

MCP8026-MOSFET driver interconnections

3.3V analog and digital filter and feedback network

dsPIC DSC internal operational amplifiers for amplifying Bus Current

Bootstrap network.

Figure A-2

2 of 4

In-System Serial Programming Header ISP1

CAN Communication Interface Header P5

External PWM speed control Interface Header P2

Serial Debugger Interface P3

Figure A-3

3 of 4

DC Bus voltage scaling resistor divider

Back-emf voltage scaling network

Op-Amp gain and reference circuitry for phase current sensing

Figure A-4

4 of 4

Motor Control Inverter –Three-phase MOSFET bridge

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MICROCHIP dsPIC33EP32MC204 User guide

MICROCHIP dsPIC33EP32MC204 User guide

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